2000 ford excursion 7.3 diesel problems

Fixing Common 7.3 Powerstroke Problems

Believe it or not, the legendary 7.3 Powerstroke diesel engine is not problem free.

Common 7.3 Powerstroke problems can develop over the course of its lifecycle and those hundreds of thousands of miles.

Here are the most common 7.3 problems, how to spot them, and how-to articles on fixing them.

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7.3 Powerstroke Problems are Un common

Like a gritty old hunting dog that just won’t quit, your 7.3 Powerstroke diesel engine has officially become a legend. But despite being called the “best Powerstroke Ford ever built” and over 15 years since the last 7.3 left the production line, 7.3 Powerstroke problems are not as uncommon as you’ve been led to believe.

But the good news is, that as common as 7.3 Powerstroke problems are, most of the fixes for them are pretty straight forward.

Time, tools, and some tenacity go a long way in DIY repairing your 7.3 diesel’s most common problems. You bring those and we’ll show you where to point them…

Top 10 7.3 Powerstroke Common Problems

7.3 powerstroke common problem #1 – 7.3 cps–camshaft position sensor.

The failure of this sensor would create a no start condition or would shut the truck off as you were driving. An easy way to diagnose a failed CPS is to check for tach movement when you crank the engine over. If the tachometer doesn’t move, the CPS is probably bad.**

**Careful though, because after 2001 Ford changed the way the tach received electrical signal and this is no longer a reliable method to troubleshoot the CPS. Read this article for details on 7.3 CPS troubleshooting and replacement.

Read the 7.3 CPS article – 7.3 CPS-Cam Position Sensor

7.3 powerstroke common problem #2 – 7.3 fuel bowl – fuel filter/water separator.

The filter housing develops cracks in the aluminum housing and leaks fuel. The heating element inside the fuel bowl filter housing can short out, blowing a fuse and causing no start. And the o-rings on the fuel filter drain lever on the back of the fuel bowl assembly would corrode and leak.

7.3 Powerstroke Common Problem #3 – Leaking turbocharger up-pipes

The pipes can leak from many points but most commonly at the joints. Leaking of the up-pipes causes the engine to lose power and for exhaust gas temps–EGTs–to increase.

7.3 Powerstroke Common Problem #4 – EBPV failure.

Aged Exhaust Back Pressure Valves would open up in cold weather and stick on. This would cause a loud whining, “jet-engine” noise to come from the exhaust.

7.3 Powerstroke Common Problem #5 – Fraying and/or melted electrical wiring

Many 7.3 common problems were due to worn, fraying, and/or melted wires. The under valve cover harness–UVCH–would stop communicating with the glow plugs or injectors. This would cause rough starting and/or misfires.

7.3 Powerstroke Common Problem #6 – Valvetrain

7.3 Powerstroke valve springs didn’t have a high seat pressure. This led to valve float at high RPM’s sometimes causing bent or broken pushrods. Aftermarket springs and shims are available to solve the problem.

7.3 Powerstroke Common Problem #7 – IPR

Injection Pressure Regulator is a valve on the 7.3 high pressure oil pump. It can stick, get leaking o-rings, fail, or have a faulty connector. Read this article for more detail on troubleshooting and fixing the 7.3 IPR.

Read the 7.3 IPR article – 7.3 IPR – Injection Pressure Regulator

7.3 powerstroke common problem #8 – overheated engine.

Several things can cause your 7.3 to overheat. Rusted thermostat, worn or perforated radiator, a failed 7.3 water pump, running the wrong or bad coolant, and/or a broken engine cooling fan.

Read DHD’s 7.3 Water Pump Leak Article – Fixing a 7.3 Water Pump Leak

7.3 powerstroke common problem #9 – fuel bowl heater.

The 7.3 fuel bowl heater element sits at the bottom of the fuel bowl. A common problem with it, especially as your Powerstroke ages, is that it can blow the maxi fuse and/or fail or short itself out. When that happens it disables the PCM–Powertrain Control Module.

7.3 Powerstroke Common Problem #10 – ICP

A 7.3 Injection Control Pressure sensor–ICP–sensor failure, will make your diesel engine run rough . You can check to see if the 7.3 ICP is causing that rough running by unplugging it.

The PCM will then use default settings for the ICP and the rough running should go away.

Read DHD’s 7.3 ICP Article – 7.3 ICP – Injection Control Pressure Sensor

Fixes for other common 7.3 problems.

Click for a list of all of our 7.3 Powerstroke maintenance, repair, and information articles .

I'm Steve. I've owned over a dozen diesel pickup trucks in my life and always worked on them myself. I'm the owner of Dead Head Diesel. I live in California. You know, the diesel "friendly" state.

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2000 7.3L Excursion Starting Issues

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I picked up the Excursion a few days ago, theft light blinking rapidly – was said to be because of the 6 position chip that was installed. Started everytime with no issue. Come to the problem, the truck sat overnight for 1 day without being plugged in (it was the coldest day we've had this week), and yesterday would not start, cranked but would not fire – theft light still blinking. Mechanic thinks its a PATS issue because of the theft light (his scanner showed U1147/U1262 - which seems to be PATS/PCM communication, but if PATS is disabled - with the tune - then I guess this should happen), and wanted to have it towed to Ford to diagnose – I of course opted not to do that being that the light had always blinked for me every day, and after reading through pages and pages, seems that the theft light does blink rapidly with a 6 position chip, and is 'normal'. Maybe, maybe not? So, after 2 hours of trying to get it to start, we got nothing. Tried the PATS reset procedure, start in neutral, keep the key in for 15 minutes, etc etc. At this point the batteries were drained, and wouldnt even crank. At last resort I thought why not plug in the block heater maybe it was too cold, and at the same time we put a jumper box on one of the batteries. Not even two minutes later, we inserted the ignotion key in and out of the lock cylinder a few times for ####s and giggles and went to start it and it fired right up. Not sure if it is related to PATS, the batteries, some other starting issue, or from it being so cold (not sure the block heater plugged in for 2 minutes would 'warm it up' but I could be wrong)? It has only been a day, but since that time it has started every time, drives fine – theft light still blinking. My question is, does this sound like something with the PATS, or loose wires or something electronic like that, or does it sound like some other starting issue? The battery voltage on the dash indicator seems good, but could it be a battery issue some how the truck not getting enough juice to start after sitting? Could the truck have been too cold and warmed up after 2 minutes with the block heater? Anyone run into something similar? Please help, thank you in advance.  

How long have you had this Excursion? Did it start this morning in the cold? Did you have it plugged in? Here's what I would probably do: 1. Ignore the blinking light. Mine has been blinking for 80k+ miles and it hasn't caused an issue. 2. Watch this video. 3. Get an injector buzz test performed. If it is a hard start/no start when cold, but starts much easier after the block heater is plugged in, there's a very good chance that you have sticking injectors like the one vehicle in the video.  

Less than a week. It didn't start one time - thinking something simple as the batteries or maybe the injectors. It appears the tune is pretty new, and it doesn't blow any black smoke in any setting, even on 140. I've read some places that the newer tunes don't smoke.. Not sure how true that is - or does it sound like a problem by not smoking on the 140 tune?  

No smoke is preferable to me. Smoke = wasted fuel. Did you watch the video? He writes that 3 or more sticking injectors will cause a no start. My bet is that you have some sticking that need replaced. It wouldn't hurt to have the batteries tested, as well. I run Interstate batteries. Also, read this. Sounds like the same issue to me. https://swampsdiesel.com/files/7.3LInjectorDiagnostic.pdf  

I agree, my THEFT light blinks due to my TW chip. Another possible issue could be a weak starter which would pull more juice and turn over slower causing poor starts when cold.  

so, truck would only start when plugged in. and fired right up each time after being plugged in. both the glow plug and intake heater relay turned out to be bad. waiting to swap these out, will post up if still no dice. I have to investigate the tune, to see whats going on with that. fun fun. thanks for the input everyone!  

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'01 Excursion Transmission Problem

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I have a 2001 Ford Excursion 4x4 with the 7.3 Diesel, 110,000 miles. I'm out of town, working in Atlanta, and my transmission has started acting up. It revs way up in 1st, and I have to let off completely to get her to drop into 2nd (hard shift). From there it seems to shift okay. The OD light started flashing when the problem started. I took the truck to a shop (complete crap shoot) this morning and they pulled codes 0732 and 0781. Their guy says he thinks it's a bad clutch and recommends rebuilding the transmission for $2000. I've been reading all the posts about this and it seems like there are lots of electrical issues that can cause these symptoms. I don't want to rebuild the transmission if its just a sensor. How can I troubleshoot the problem? Not sure if its relevant, but the day before the problem started I launched a boat and had to back pretty far into the water (Wet VSS?), and it's been wet and rainy all weekend. Also, I had to replace the alternator on the drive out here when it failed. Thanks in advance for your help and advice!  

It isn't anything electrical. This is a very common failure in the 2001 diesels. It is a failed mechanical diode one way clutch. The transmission has to be rebuilt to fix this. There is no easy or cheap way.  

Thanks Mark... Wishful thinking I guess. Does anyone know of a reputable transmission shop around Atlanta? Would I do further damage if I try to drive her back home? Are there any recommended upgrades, rebuild kits, etc that I should consider while I'm at it? Thanks!  

I have a 2001 excursion with the 7.3 engine. the trans mission has quit except for reverse. I live near Frederick Maryland can anyone recommend a trustworthy shop. amco rebuilt it 5 years ago. Thanks  

Ford dealers can install one of Ford's re-manufactured units that carry a Ford warranty. At one time a heavy duty Ford transmission was available through a Ford dealership, but I do not know if that is still the case.  

TooCoolTwo said: Ford dealers can install one of Ford's re-manufactured units that carry a Ford warranty. At one time a heavy duty Ford transmission was available through a Ford dealership, but I do not know if that is still the case. Click to expand...

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Cascio Motors Is Selling a Diesel-Powered Excursion on Bring a Trailer

Explore the features and history of the 2000 Ford Excursion Limited, a rare find powered by a robust 7.3-liter Power Stroke turbodiesel V8.

A standout in its class, the 2000 Ford Excursion Limited , originally sold by Russ Dean Ford in Pasco, Washington, boasts an impressive pedigree. This well-traveled vehicle has been registered in multiple states, including Washington, California, and Arizona, adding to its rich history. Under the hood lies a formidable 7.3-liter Power Stroke turbodiesel V8 engine, paired with a four-speed automatic transmission, a dual-range transfer case, and a limited-slip rear differential, ensuring exceptional performance both on and off the road.

Finished in striking Estate Green Metallic and adorned with beige lower body cladding, this Excursion Limited features a host of desirable amenities. From the Mishimoto aluminum radiator to the Banks Power air intake and rear differential cover, every detail reflects quality craftsmanship. The interior offers three rows of seating upholstered in Medium Parchment leather, complemented by air conditioning, power windows and door locks, and a CD stereo system for added comfort and convenience.

Despite its 267k miles, this Excursion Limited has been meticulously maintained, with recent repairs including a transmission rebuild and fuel injector replacement. Offered by the selling dealer at no reserve, this exceptional vehicle comes complete with a window sticker, owner’s manual, service records, and a clean Carfax report, presenting a rare opportunity for discerning buyers to own a piece of automotive history. Whether for daily driving or off-road adventures, the 2000 Ford Excursion Limited stands as a testament to durability, performance, and timeless style.

Cascio Motors is a leading seller on Bring a Trailer. Visit their website to learn more about consignment and to see their other great inventory.

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2000 Ford Limited 7.3 Diesel Excursion - $18,000 (Castaic)

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2000 Ford Excursion Limited 7.3 Power Stroke Diesel, 4x4 I am 2nd owner, runs great, no problems. 8” lift, Nito trail grapplers. 38” x 15.5” x 20” tires w/ custom machines aluminum Centerline rims....

Moscow authorities have closed the western Slavyansky Bulvar and Park Pobedy metro stations on the Dark Blue Line and restricted traffic on the thoroughfare Kutuzovsky Prospekt until at least 10 p.m. Tuesday following a crash on the metro.

Buses marked "M" are taking over the closed-off metro route, running from the central Kievsky Station to the Molodyozhnaya metro station, the metro website said.

Deputy Mayor Maxim Liksutov said in comments carried by the Interfax news agency that traffic on Kutuzovsky Prospekt was being restricted until at least 10 p.m. to make way for the buses taking over the metro route.

A metro official said that about 150 extra buses will be running the route.

At least 20 people were killed and about 120 people injured when three metro cars derailed and crashed after a sudden power failure during rush hour on Tuesday morning.

20 Dead in Tragic Moscow Metro Rush-Hour Crash

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7.3 Alternator issues

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My 2002 Excursion is going through alternators about every four months. Anyone else having this issue and is there a solution? Thanks  

My dad has a 97 f350 7.3 and we have put 3 alternators on it in the last two years. I cant figure out what the deal is.  

What kind of alternators are you putting on it? Are they new or rebuilt? Where are you buying them from? How old are the batteries? Have they been tested recently?  

I know this is a late response but it may help someone. Had this issue on a company truck years ago. After many alternators and a wiring harness we discovered the glow plug relay was sticking. After correcting the issue and driving a few more miles a glow plug came apart and went through a cylinder. I recommend replacing the relay and plugs. That is what fixed that one. Well a long block fixed the plug issue so i recommend doing them before they come apart if this in fact your issue.  

The alternator harness goes bad and it will eat alternators. There is a replacement harness available. Seen 2 trucks with this problem, new harness fixed both.  

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Victor Mukhin

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Title : Active carbons as nanoporous materials for solving of environmental problems

However, up to now, the main carriers of catalytic additives have been mineral sorbents: silica gels, alumogels. This is obviously due to the fact that they consist of pure homogeneous components SiO2 and Al2O3, respectively. It is generally known that impurities, especially the ash elements, are catalytic poisons that reduce the effectiveness of the catalyst. Therefore, carbon sorbents with 5-15% by weight of ash elements in their composition are not used in the above mentioned technologies. However, in such an important field as a gas-mask technique, carbon sorbents (active carbons) are carriers of catalytic additives, providing effective protection of a person against any types of potent poisonous substances (PPS). In ESPE “JSC "Neorganika" there has been developed the technology of unique ashless spherical carbon carrier-catalysts by the method of liquid forming of furfural copolymers with subsequent gas-vapor activation, brand PAC. Active carbons PAC have 100% qualitative characteristics of the three main properties of carbon sorbents: strength - 100%, the proportion of sorbing pores in the pore space – 100%, purity - 100% (ash content is close to zero). A particularly outstanding feature of active PAC carbons is their uniquely high mechanical compressive strength of 740 ± 40 MPa, which is 3-7 times larger than that of  such materials as granite, quartzite, electric coal, and is comparable to the value for cast iron - 400-1000 MPa. This allows the PAC to operate under severe conditions in moving and fluidized beds.  Obviously, it is time to actively develop catalysts based on PAC sorbents for oil refining, petrochemicals, gas processing and various technologies of organic synthesis.

Victor M. Mukhin was born in 1946 in the town of Orsk, Russia. In 1970 he graduated the Technological Institute in Leningrad. Victor M. Mukhin was directed to work to the scientific-industrial organization "Neorganika" (Elektrostal, Moscow region) where he is working during 47 years, at present as the head of the laboratory of carbon sorbents.     Victor M. Mukhin defended a Ph. D. thesis and a doctoral thesis at the Mendeleev University of Chemical Technology of Russia (in 1979 and 1997 accordingly). Professor of Mendeleev University of Chemical Technology of Russia. Scientific interests: production, investigation and application of active carbons, technological and ecological carbon-adsorptive processes, environmental protection, production of ecologically clean food.   

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